PolyJohn SH1 Fleet Series Assembly Manual

SH1 Fleet™ Shower Series

Cold Water Shower Model

Assembly Manual

U.S. PATENTS: 5,500,960 - 5,500,962 - 5,560,050 - 6,199,222 D 360,471

SPECIFICATIONS

DIMENSION IMPERIAL METRIC

Exterior Height 91 in 231 cm

Interior Height 83 in 211 cm

Exterior Width 47 in 119 cm

Interior Width 45.7 in 116 cm

Exterior Length (Runner Base) 48 in 122 cm

Exterior Length (Optional
Signature Style Handle Base) 47 in 119 cm

Interior Length 43 in 109 cm

Weight 195 lb. 88 kg

Door Frame Height (ID) 75 in 191 cm

Door Frame Width (ID) 26 in 66 cm

Side Panel Decal Area 6 in X 37 in 15 cm X 94 cm

Door Decal Area 22.5 in X 29 in 57 cm X 74 cm

POLYJOHN

USA

PolyJohn Enterprises Corp.

2500 Gaspar Ave.

Whiting, IN 46394

Phone: [phone]

Fax: [phone]
www.polyjohn.com
[e-mail]

POLYJOHN

WORLDWIDE

PolyJohn (UK) Ltd.

Equinox 1 Audby Lane

Wetherby, England LS22 7RD

Phone: [phone]

Fax: [phone]

www.polyjohn.co.uk

[e-mail]

SH1-1 Assembly - July 2012

Page 1 of 12

POLYJOHN

CANADA

PolyJohn Canada

P.O. Box 2300

199 Forest Plain Rd.

Orillia, Ontario LV3 6S2

Phone: [phone]

Fax: [phone]
www.polyjohncanada.ca
[e-mail]

Clothes Hook

(4) PC-000102 Rivet

(2) PC-100538

FS1-0061 Top Rear Extrusion

(5) PC-000104 Rivet

(3) SG1-0037 Inner Screen

(3) SG1-0038 Outer Screen

SH1-0007 Curtain Rod

(6) PC-000102 Rivet

(6) PC-000106 Washer

FS1-0062 Left Rear Extrusion

SH1-0012* Rear Panel

(4) PC-000192 Sems Screw

FS1-0063 Right Rear Extrusion

(9) PC-000104 Rivet

(9) PC-000104 Rivet

SH1-0005 Shower Curtain

SH1-0006 Curtain Hooks

PC-100536 2” PVC Drain Pipe

PC-000419 2” Uniseal

(16) PC-000158 Screws

SH1-0080 Shower Grate

SH1-0031 Intake Elbow

PC-100567 Escuschion Plate

(2) PC-000105 Rivet

PC-100565 -

Self Closing Valve

SH1-0001 Shower Pan

(4) PC-000192 Sems Screw

SH1-0004 Perimeter Seal (not shown)

FS3-0018 Handle/Runner Base

FS3-0019 Handle Signature Style Base (Optional)

FS1-0007 Roof Panel

(3) PC-000100 Rivet

(3) PC-000106 Washer

(3) PC-000121 Washer

SH1-1000 Cold Shower

Parts Listing

SH1-0021 Shower Body

(1) PC-000105 Rivet

(1) PC-000121 Washer

SH1-0030 Shower Elbow

*Must specify color when

ordering replacement parts

SH1-0012 Shower Head

(2) PC-100541 Curtain Rod Flanges

(6) PC-000104 Rivet

(6) PC-000106 Washer

(2) SG1-0035 Large Screen

(2) PC-000102 Rivet

(2) PC-000106 Washer

(2) FS1-0002* Side Panel

(10) PC-000192 Sems Screw

PC-000181S Spring Clip

(2) PC-000104 Rivet

SG1-0030 Slide Latch

SG1-0031C Slide Latch Cover Plate

SG1-0031 Slide Cover Plate

SA1-0017 Handle U Bolt

(2) PC-100134 Handle Screws

(2) PC-100796 Grommet

SG1-0032 Retain Plate

SG1-0033 Slide Plate

TM01-0003 Mirror

PC-000367 Push-In Fastener

FS3-0003* Front Assembly

(17) PC-000104 Rivet

(4) PC-000159 1/4-20 x 3-1/2” Bolt

(4) PC-000123 Washer

(4) PC-000140 Nylock Nut

-FS3-0060 Door Jamb

-PC-100787 Serial I.D. Plate

-(2) PC-000108 Rivet

-FS1-0005*C Complete Door

--FS1-0005* Fleet Door

--(3) PC-100170 Hinge Assembly

--(6) PC-000116 Rivet

--(3) PC-000160 5/16” x 3/4” Bolt

--(3) PC-000161 5/16” Flat Washer

--(3) SG1-0037 Inner Screen

--(3) SG1-0038 Outer Screen

--(6) PC-000104 Rivet

--(6) PC-000106 Washer

FS1-0034* Door Panel Cover

(4) PC-000158 Screw

(2) PC-000147 Screw

PC-000800 Spring Assembly

GENERAL OVERVIEW

•These instructions are for showers shipped unassembled. Please retain these instructions for maintenance and repair purposes.

•The SH1-1 Model shower assembly will require two people.

•All references to left, right, front and rear are as viewed from the front of the shower.

•Review the entire instruction manual prior to assembly.

•Please follow the instructions in the order they are presented.

•When using air operated screw drivers or impact wrenches, be sure that the torque setting does not exceed 28 inch pounds.
Also, when using a battery-operated drill, set it to the lowest torque setting.

•We strongly suggest that these showers, as with all portable structures, be transported and handled with care. Dropping the
shower when loading and unloading could cause damage to the door jamb and other components.

~~TOOLS REQUIRED FOR ASSEMBLY~~

• Rivet Gun • Standard Slotted Screwdriver • Phillips Crosshead Screwdriver • Vise-Grips • Pliers

• Te on Tape • (2) Tapered Awls • Drill with a 13/64” and 1” Drill Bit • Socket Wrench with a 7/16” socket

FULL SCALE FASTENER DRAWINGS

(3) PC-000100 - Rivet

(6) PC-000102 - Rivet

(48) PC-000104 - Rivet

(3) PC-000105 - Rivet

(4) PC-000140 Lock Nut

(11) PC-000106 - Washer

(4) PC-000123 - Washer

(2) PC-000147

3/4” Long SM Screw

(4) PC-000158

1-1/2” Long SM Screw

(18) PC-000192 Sems

(4) PC-000121 - Washer

(4) PC-000159 - Screw

SH1-1 Assembly - July 2012

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(4) PC-000367 - Nylon

Push-In Fastener

Step 1: Shower Pan to Base

Insert the PC-000419 Uni-Seal into the hole at the bottom of
the shower sump. Place the shower pan on the base, with
the drain going towards the rear. Take the 2” drain pipe
supplied, and insert it through the hole in the rear of the
unit and into the Uni-seal in the bottom of the shower pan.
A lubricant, such as dish soap would help in getting the
pipe completely inserted into the uni-seal.

Step 2: Sidewall Panels to Rear Extrusions and Rear Wall Panel

Slide a plastic rear extrusion onto each side of the rear
panel making sure that the mitered ends are towards the
top of the rear panel (where the  y screens are, and the

ribbed side of the extrusions are facing toward the outside
of the shower). Line up the holes in the rear extrusions

with the holes in the rear wall panels. Insert awls into the
center holes. Slide the right side wall panel (with hatch in
corner) into the corresponding slot of the rear extrusion
and remove the awl from that rear extrusion. Line up all
of the holes and rivet from the inside, the rear extrusions,
rear wall panel and side wall panel together using small
 ange, rivets, PC-000104. DO NOT RIVET THE TOP HOLE
IN EITHER OF THE EXTRUSIONS AT THIS TIME. Remove
the awl in the left extrusion and rivet together the left side
wall panel, left rear extrusion, and rear panel, leaving the
top hole for later.

Right Rear Extrusion

Rear Panel

PC-000104 Rivet

SH1-1 Assembly - July 2012

Page 4 of 12

Right Side

PC-000104 Rivet

(16) Used in this step

Step 3: Sidewall Panels to Door Jamb

Insert the edge of the left side panel into the slot on the left side of the door jamb. Line up the holes in the jamb with the
corresponding holes in the side panel. Rivet the second and third holes from the bottom as well as the top two holes using

(4) PC-000104 rivets (as shown on the left). Using holes in the jamb as a guide, drill
three 13/64” holes into the side panel. Rivet the PC-000181S cable clip at the center
two holes of the jamb using (2) PC-000104 rivets. Rivet the bottom hole using the
same rivet. Wrap the cabana around the base of the unit resting the bottom edge of
the sides on the ledge around the base. Slide the edge of the right side wall panel
into the slot in the jamb. Line up the holes in the side panel with the corresponding
holes in the jamb and rivet in place using (4) PC-000104 rivets. DO NOT RIVET THE
SECOND HOLE FROM THE TOP AT THIS TIME. Using a drill with a 13/64” drill bit,
drill out the third hole from the top as well as the bottom hole. Rivet the bottom
hole using a PC-000104 rivet.

PC-000104 Rivet
(14) Used in this step

Step 4: Cabana to Base

Insert (4) PC-000159 bolts through the holes at the bottom of the jamb and
into the slots in the base. On the back-side of the unit, center the rear panel on
the base. Fasten the rear panel to the base using (4) PC-000192 sems. Gently
lay the unit on it’s back. Place (4) PC-000123 washers and (4) PC-000140 nuts
on the PC-000159 bolts at the front of the base, but DO NOT TIGHTEN AT

THIS TIME. Close the door and tighten the bottom bolts (making sure that
there is a 1/4” gap between the latch side of the door and the jamb). Open the

door and tighten the top bolts.

PC-000123 Washers
and PC-000140 Nuts

1/4” Gap Between
Door and Jamb

PC-000123 - Washer
(4) Used in this step

PC-000140 Lock Nut

(4) Used in this step

PC-000192 Sems

(4) Used in this step

SH1-1 Assembly - July 2012

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PC-000159 - Screw

(4) Used in this step

Step 4: Cabana to Base Cont.

9 1

3

4

14

2

Carefully stand the unit upright. Starting with
the left of the unit, drive a PC-000192 sems screw
through the pre-drilled hole in the front of the

8

13

side panel. BE SURE NOT TO OVERTIGHTEN
AND STRIP OUT THE PLASTIC. Continue around

the left side of the unit, until you reach the rear
extrusion. Repeat this process with the right side

7

6

5

10

12

11

of the unit, starting with the front.

PC-000192 Sems
(18) Used in this step

Fasten the shower pan in place by driving in (4)
PC-000192 Lag screws on either side of the door
jamb and on either side of the rear extrusions as
shown in the  gure to the right. BE SURE NOT TO

OVERTIGHTEN AND STRIP OUT THE PLASTIC.

Step 5: Screen Installation

Take a SG1-0035 large  y screen and place the bottom
curved  anges onto the top of the right side panel (as
shown on the right.) Tilt the top of the  y screen up into
place. Using the hole in the bottom, middle  ange as a
guide, drill a 13/64” hole through the side panel. Rivet
in place using a PC-000102 rivet from the inside with a
PC-000106 back-up washer on the outside. Repeat this
step with the left side.

PC-000102 Rivet
(2) Used in this step

PC-000106 Washer

(2) Used in this step

SH1-1 Assembly - July 2012

Page 6 of 12

Step 6: Roof Installation

Place the FS1-0061 top extrusion on the top edge of
the rear panel so that the miters line up with the left
and right extrusions, and that the grooved surface is
facing the outside. Place the roof on the top of the
unit with the arch in the roof going into the groove in
the top of the jamb. Put the rear edge of the roof in
the groove in the top rear extrusion. With someone
pushing down on the back of the roof, use the holes in
the rear extrusion as a drill guide, drill  ve 13/64” holes
into the roof. MAKE SURE TO ONLY DRILL THROUGH

THE ROOF AND NOT THROUGH THE BACK OF THE
TOP REAR EXTRUSION. Rivet the top holes in both the

left and right rear extrusions as well as the  ve holes
of the top rear extrusion using (7) PC-000104 rivets.
Push down on the front of the roof while using the
holes in the jamb as a drill guide, drill  ve 13/64” holes
through the roof. Rivet in place using (5) PC-000104
rivets. Locate the holes in the top of each of the side
panels. Push out on the top of the side panel, and
using a 13/64” drill bit, drill a hole through the hole in the top of the side, and through the roof. Rivet in place using a PC­000100 rivet on the inside with a PC-000121 washer and a PC-000106 back-up washer on the topside of the roof. Repeat
for all the holes in the top of the side panels but do not fasten the one closest to the hole for the vent stack at this time.

PC-000104 Rivet
(12) Used in this step

Step 7: Shower Assembly Installation

On the inside of the unit, push the top of the shower assembly plastic
body up into the vent stack hole in the left rear corner of the roof. Using
a black felt tipped marker, mark the spot where the hole in the shower
body lines up with the top of the side panel. Remove the shower body
from the vent stack hole, and drill a 1” hole through the side and roof in
the location just marked. Place the shower body back up into the vent
stack hole, and make sure that the hole that was drilled lines up with
the molded through hole in the shower body. With someone holding
the shower body in place, drill a 13/64” hole through the hole in the top
of the roof (that was drilled in step 6), and into the shower body. Rivet
in place using a PC-000105 rivet with a PC-000121 washer behind the
head of the rivet.

PC-000121 Washer

(3) Used in this step

PC-000100 Rivet
(3) Used in this step

Marker

PC-000106 Washer

(3) Used in this step

PC-000105 - Rivet

(1) Used in this step

PC-000121 Washer

(1) Used in this step

SH1-1 Assembly - July 2012

Page 7 of 12

Step 7: Shower Assembly Installation Cont.

Refer to the diagram on the left for the placement of the plumbing parts. Insert the PC-100565 shower valve into the molded

in recess in the shower body. Wrap some Te on tape around the threads on the

SH1-0031 Shower Intake pipe and the SH1-0030 Shower head

assembly. From the outside of the unit, place the PC-100567

Escutcheon plate over the end of the SH1-0031 Shower Intake
pipe and thread the intake pipe through the hole and into the

shower valve. Make sure that the hose connection is pointing

down and that the connection is tight. Fasten the Escutcheon plate to

the outside of the unit by drilling two holes into the roof, side panel,

and shower body through the two molded through holes in the plate.
Rivet in place using (2) PC-000105 rivets. On the inside of the unit,

thread the Shower head assembly through the molded in hole of the

shower body and into the shower valve. Tighten all the way, making sure

that the shower head points down.

PC-000105 - Rivet

(2) Used in this step

Step 8: Spring Installation

From the front of the door, insert the cable end of the spring assembly into
the 1/2” hole in the door. Make sure that the 1/2” boss in the end cap of the
spring assembly is pushed through the hole. On the inside of the unit, place
the top of a hammer against the PC-000181S spring cable clip (as shown on
the right). Place the end of the spring cable in the claw of the hammer.

Open the door while holding
the hammer in position.
Hold the door open with
your foot, and clamp a vice-grips pliers on the cable where it comes out
of the door. BE SURE TO CLAMP DOWN TIGHT. Remove the cable from
the claw of the hammer, close the door, and place the end of the cable
into the slot of the cable clip. Open the door, and remove the vice-grips.

SH1-1 Assembly - July 2012

Page 8 of 12

Step 9: Optional Lock Installation

Place the tip of a screwdriver in the lock area of the Door Trim Panel
(as shown on the right). Strike the handle end of the screwdriver
with a hammer to “knockout” the plastic  lling the hole for the lock.
Remove the nut from the end of the lock, and insert the lock through
the hole of the Door Trim Panel from the outside. Re-insert the nut
back on the lock and tighten down. Insert the key and turn the lock
to the right and remove the key (this is the locked position which is

needed at this point to check the lock for proper installation with the Slide
Latch mechanism which is installed in the next step). NOTE: Turning

the key upright is the neutral or normal use position which allows the
Slide Latch to move into the “Open/In-Use” position when persons
are inside the shower. Turning the key to the left is the open position
and the key can not be removed until either in the “Open/In-Use” or
“Locked” position.

Step 10: Door Panel /Slide Latch Installation

Snap the Unisex Indicator Plate into the back of the Door Trim Panel. Place the Door
Trim Panel into the recess in the front of the door. While holding the Door Trim
Panel in position, place the Slide Latch and Slide Latch Cover Plate on the inside
of the door and line up the holes of the Slide Latch Cover Plate, the Door, and the
Door Trim Panel. Insert (4) PC-000158 screws and tighten. NOTE: These screws

should be tightened to the point where they will interfere with the sliding action of
the Slide Latch and then backed o slightly, leaving enough friction to prevent the Slide
Latch from sliding into the “In-Use/Open” position when the door shuts. The U Shaped
handle prevents persons from inadvertently moving the slide
latch to the “In-Use” position when exiting the
restroom. Insert the  ip “Male-Female” Indicator

Plate into the slot on the top edge of the Door
Trim Panel (above where the Unisex Indicator Plate
is located). Insert (2) PC-000147 screws into the
holes toward the hinged side of the door, line up
with the holes in the Door Trim Panel, and tighten.
If the optional lock is installed, unlock the lock by
inserting the key into the lock and turning to the
left and back to the upright position which is the
neutral or normal use position and remove the
key (this allows the Slide Latch to move into the

“Open/In-Use” position when persons are inside
the shower). Turn the key to the right and remove
the key for the locked position. Turning the key to
the left indicates the open position and the key can
not be removed until either in the “Open/In-Use” or
“Locked” position. IMPORTANT: The punched

1/4” hole in the center of the Slide Latch where
the “In-Use/Open” stamp is imprinted complies
with code enabling the door to be unlocked
from outside the shower in the event of distress
and a person inside were unable to unlock the
door. A POINTED OBJECT INSERTED INTO THE
HOLE AND MOVING THE SLIDE LATCH TO THE
LEFT WILL ALLOW THE DOOR TO BE OPENED
PROVIDING THE DOOR HAS NOT BEEN LOCKED
WITH THE KEY.

PC-000158 Screw

(4) Used in this step

PC-000147 Screw

(2) Used in this step

SH1-1 Assembly - July 2012

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Step 11: Clothes Hooks, Shower Curtain and Hanging Rod

Using the PC-100538 coat hook as a drill guide, hold it up against the top diagonal
corners (left and right as shown) towards the door and drill two 13/64” diameter
holes. Rivet each hook in place from the outside with (2) PC-000102 rivets.
The shower curtain rod is a three-piece assembly consisting of two  anges and one
1” diameter x 39 ¾” long tube. Position the  anges on the long tube. Use the  anges
as a drill guide and drill three 13/64” diameter holes. Be sure to drill only through
the side panel, and not through the roof. Make these holes on a vertical plane, top to
bottom, for more strength. Rivet in place from the inside using (3) PC-000104 rivets
per  ange with (3) PC-000106 back-up washers on the outside. Make sure the long
tube is level. Drill and rivet the other  ange in place. Add the shower curtain hooks
to the shower curtain; slip them over the curtain rod and snap in place.

PC-000102 Rivet

(4) Used in this step

General Use and Maintenance

Locking/Unlocking the Unit (Optional)

If this unit is equipped with an optional exterior lock, it can be locked to prevent unwanted usage in the evening or
weekend hours when no one is onsite. This is done by turning the lock to the right and removing the key. When it comes
time to unlock the unit, insert the key and turn all the way to the left, and then back to the upright position.

Hooking Up the Fresh Water Connection

To connect the fresh water to the unit, connect a garden hose to a pressurised fresh water supply, and to the fresh
water connection coming out of the top rear of the unit.

Hooking Up the Waste Water Connection

The waste water drains though the 2” PVC pipe coming out of the rear of the unit. We recommend the use of a Fernco
2” rubber coupler to connect to a pipe that will carry the waste water away from the shower unit. The waste water
storage must be lower than the unit, otherwise the waste water will back up into the unit.

PC-000104 Rivet

(6) Used in this step

PC-000106 Washer

(6) Used in this step

SH1-1 Assembly - July 2012

Page 10 of 12

CLEANING AND MAINTENANCE

• Use a mild soap to clean all surfaces and component parts.

• The mirror is acrylic, do not use solvent based cleaners, use only a mild liquid soap. To maintain a gloss, use a  annel cloth with a
good plastic cleaner or polish (such as “Johnson’s Pledge”).

• Minor scratches and abrasions can be lightly sanded or scrubbed with a mild abrasive cleaner (such as “Soft Scrub”) that contains
calcium carbonate, hypochlorate bleach and detergents. Be sure to follow the cleaning product directions since these
ingredients may cause hazardous gases when mixed with other chemicals. Rinse the cleaned area and bu with a conventional
wax.

• Some light scratches may also be hidden by using an industrial hot air gun.

• To keep the interior smelling fresh, spray the interior with a deodorant spray.

For a source of cleaning, deodorizing and paper products contact:

COOPER’S OWN

2500 GASPAR AVE.

WHITING, IN 46394-2175

OLL FREE: 800-292-1305

T

www.polyjohn.com/coopers_own.php

We highly recommend membership in the Portable Sanitation Association International (PSAI); the worldwide authority on portable
sanitation services. The PSAI, “Portable Sanitation Industry Certi cation Program” manual contains a wealth of information on standards
and service procedures. For more information contact the PSAI:

PORTABLE SANITATION ASSOCIATION INTERNATIONAL (PSAI)

7800 METRO PARKWAY, SUITE 104

BLOOMINGTON, MINNESOTA 55425 USA

800-822-3020 / 612-854-8300 FAX [phone]

www.psai.org

OUR MISSION STATEMENT

“PolyJohn is a family owned, state of the art, plastics manufacturing company dedicated to providing its employees with a work
environment committed to excellence, and its customers with innovative products, services and technology that meet or exceed
their requirements.”

THANK YOU FOR PURCHASING POLYJOHN PRODUCTS!

Look for us on the web @PolyJohn.com

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